Method for wet mixing cementitious slurry for fiber-reinforced structural cement panels

Abstract

A process employing a wet mixer having a vertical mixing chamber for forming a wet slurry of a cementitious powder and liquid. The vertical mixing chamber is designed to provide the required amount of mixing to provide thoroughly mixed, uniformly thin slurry within a mixing residence time that allows for adequate supply of slurry to ensure continuous operation of an associated cement panel production line. Gravity feed for supply of cementitious powder and water to the slurry mixing area of the chamber is also disclosed.

What is claimed is: 
     
       1. A method for preparing lightweight cement composite slurry which can be supplied in a continuous curtain for uniformly covering a thick layer of fiber in the production of a reinforced structural cement panel comprising:
 feeding a dry cementitious powder comprising cement, gypsum and aggregate from a bin into a horizontal powder mixer having a horizontally mounted screw auger; 
 discharging the dry cementitious powder mixture from the screw auger into a horizontal pre-mixer equipped with a paddle rotated about a central horizontal axis by the screw auger; 
 feeding a liquid stream comprising water, into the horizontal pre-mixer through an inlet; 
 mixing the cementitious powder and liquid to form a wet powder slurry mixture; 
 dropping the pre-mixed powder and liquid mixture from the upper portion of a vertically oriented mixing chamber to a lower portion of the vertically oriented mixing chamber equipped with a paddle mixer rotated about a vertical shaft by a top mounted motor; 
 mixing the water and powder in the lower portion of the vertically oriented mixing chamber; and 
 pumping the slurry to a slurry headbox for depositing the slurry as a continuous curtain on a thick fiber layer on a web in a panel production line, 
 wherein the powder and liquid are mixed for an average mixing residence time in the mixing chamber lower portion of about 10 to about 360 seconds while a spinning paddle applies shear force to the slurry in the mixing chamber to mix the powder and water to produce a uniform slurry of a lightweight cement composite that has a consistency that will allow the slurry to uniformly cover a thick layer of fiber on a web to produce a fiber reinforced structural cement panel. 
 
     
     
       2. The method of  claim 1 , wherein the vertical chamber provides an average slurry residence time of about 15 to about 240 seconds, and an RPM range of the paddle is 70 RPM to 270 RPM. 
     
     
       3. The method of  claim 1 , wherein the slurry is pumped from the bottom of the vertical chamber by a cavity pump that is run by a motor mounted on the top of the vertically oriented mixing chamber to also rotate the central shaft of the paddle. 
     
     
       4. The method of  claim 1 , wherein the paddle in the vertically oriented mixing chamber has multiple paddle blades comprising multiple horizontal blades and a central shaft that is extended to the length of the vertical oriented mixing chamber. 
     
     
       5. The method of  claim 1 , wherein the supply of powder and liquid entering the vertically oriented mixing chamber is controlled by an electronic liquid level sensor controller that continuously monitors the level of powder and water slurry in the mixing chamber. 
     
     
       6. The method of  claim 1 , wherein a gravimetric weighing system associated with the screw auger controls the rate of feed of the dry cementitious powder into the horizontally oriented pre-mixer based upon a constant predetermined weight of powder per minute. 
     
     
       7. The method of  claim 1 , wherein the dry cementitious powder comprises a reactive powder portion and an optional lightweight filler portion, wherein the reactive portion comprises, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan. 
     
     
       8. The method of  claim 1 , wherein the dry cementitious powder comprises a reactive powder portion and a lightweight filler portion, wherein the reactive portion comprises, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan. 
     
     
       9. The method of  claim 8 , wherein dry cementitious powder comprises 20 to 50% by weight of the lightweight filler particles on a dry basis. 
     
     
       10. The method of  claim 9 , wherein the lightweight filler particles are selected from the group consisting of ceramic microspheres, glass microspheres, fly ash cenospheres and perlite. 
     
     
       11. The method of  claim 1 , wherein a variable speed motor controls the screw auger to control the supply of powder to the horizontal oriented pre-mixer and the rotation of the paddles to deliver the wet powder slurry to vertically oriented mixing chamber. 
     
     
       12. The method of  claim 1 , wherein the slurry is pumped from the bottom of the vertical oriented mixing chamber by a cavity pump driven by a central shaft of the vertical mounted agitator blades which is, in turn, run by a motor mounted on the top of the vertically oriented mixing chamber.